Porous electroformed shell for patterning and manufacturing method thereof

Abstract

Disclosed are a porous electroformed shell for forming a grain pattern and a manufacturing method thereof. The method includes the step of implanting a fiber into a patterned surface of a negative-type silicone cast; applying, laminating, and curing an epoxy resin on the patterned surface of the negative-type silicone cast, and transferring the fiber from the negative-type silicone cast to an epoxy mandrel during demolding of the epoxy mandrel; forming a conductive thin film on the patterned surface of the epoxy mandrel, and causing the patterned surface to be conductive; removing the fiber having the conductive thin film from a surface of the epoxy mandrel; forming an electrodeposited layer by electrodepositing an electroforming metal on the conductive thin film while generating and growing a fine pore at a position of a hole due to the removal of the fiber; and demolding the electrodeposited layer having the fine pore from the epoxy mandrel. Through the disclosed method, precise control on a diameter and distribution of a fine pore can be simply and efficiently can be carried out.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates to a porous electroformed shell for patterning and a manufacturing method thereof, and more particularly to a porous electroformed shell for patterning and a manufacturing method thereof, allowing to economically and effectively manufacture a surface skin material or injection molded product with refined texture, which is employed in one-piece molding of a high-quality surface skin material for providing a curved surface of a specific three-dimensional cubic synthetic resin product with refined texture through various patterns of desired shapes and thereby enhancing an emotional quality.[0003]In the manufacturing method of a porous electroformed shell for patterning, according to the present invention, the overall or local formation positions, shapes, densities, and diameters of pores can be simply, economically, efficiently and precisely controlled according to various curved shapes of the...

AI Technical Summary

Benefits of technology

[0018]Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and a first object of the present invention is to provide a porous electroformed shell for patterning and a manufacturing method thereof, in which diameters, formation positions, and densities of fine pores formed on a three-dimensional electroformed shell, both as a whole or in part, can be simply, economically, efficiently, and precisely controlled according to various curved shapes of the electroformed shell.

[0019]Besides the first object, a second object of the present invention is to provide a method for economically and effectively manufacturing a patterning porous electroformed shell so as to effectively express refined, sharp, and precise texture on the surface of an injection molded product.

[0025]Preferably, in the electroforming step, a blocking wall having a height greater than an uppermost height of the epoxy mandrel by 20˜30 mm, and multiple pores formed therein may be placed in a box form at front / rear / left / right sides and an upper side of the epoxy mandrel, so as to prevent bubbles from detaching by a flow velocity of an electroforming liquid.

[0026]Preferably, in the electroforming step, the epoxy mandrel is immersed in a plating solution and then, it is electroformed after 1-2 hours so as to enhance an adhesion between the epoxy mandrel having the conductive thin film and the plating solution.

[0031]In the manufacturing method of a patterning porous electroformed shell, according to the present invention, a fiber is transferred to be conductive and then, it is removed to be electroformed, so that both as a whole or in part, diameters, formation positions, and densities of fine pores can be simply, economically, efficiently, and precisely controlled according to various curved shapes of the electroformed shell. Accordingly, in forming the surface of a high-quality surface skin material that is, skin sheet or film or a plastic molded product with a predetermined pattern, when the fine pore is used as a decompression suction hole or an air vent, a predetermined pattern can be efficiently and economically obtained in such a manner that it has a regular position, a regular directionality, sharp radii, and minimized deformation.

Problems solved by technology

Herein, in in-mold forming employing a skin material having a specific cubic pattern, for example, a natural or artificial leather grain pattern, since the skin material has an influence on an emotional quality, it has become an important issue to provide a predetermined cubic pattern to the skin material, and preform it into a predetermined three-dimensional shape.

In this method, since a burr is formed at a front side of the shell owing to the hole processing during demolding of the electroformed mold, there is a problem in that an additional process for removing the burr is demanded.

This method requires an additional electrostatic file planting apparatus, two-step electroforming processes controlled according to the length of a short fiber, and a short fiber removing process by combustion and / or solvent dissolution, and thus has a low productivity and a low economical efficiency.

This method also has a disadvantage in that the productivity and the economical efficiency are low due to complicated processes, and it is not related to local control on the density of through holes in the electroformed shell.

This method has an advantage in that it is theoretically possible to control the diameter of the fine straight hole and the whole / local density, but has a disadvantage in that physical processing of multiple fine straight holes is very complicated, uneconomic, and time consuming, thus is in actuality, not efficient at all.

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